Alkali/Transition Metal Phosphates And Related Electrode Active Materials

ABSTRACT

Electrode active materials comprising lithium or other alkali metals, a transition metal, and a phosphate or similar moiety, of the formula: 
 
A a+x M b P 1-x Si x O 4  
wherein (a) A is selected from the group consisting of Li, Na, K, and mixtures thereof, and 0&lt;a&lt;1.0 and 0&lt;x&lt;1; (b) M comprises one or more metals, comprising at least one metal which is capable of undergoing oxidation to a higher valence state, where 0&lt;b&lt;2; and wherein M, a, b, and x are selected so as to maintain electroneutrality of said compound.

This Application is a continuation of application Ser. No. 10/945,304filed Sep. 20, 2004, now allowed, which is a divisional of applicationSer. No. 10/092,317, filed Mar. 6, 2002, now U.S. Pat. No. 6,815,122.

FIELD OF THE INVENTION

This invention relates to electrode active materials, electrodes, andbatteries. In particular, this invention relates to active materialscomprising lithium or other alkali metals, transition metals, andphosphates or similar moieties.

BACKGROUND OF THE INVENTION

A wide variety of electrochemical cells, or “batteries,” are known inthe art. In general, batteries are devices that convert chemical energyinto electrical energy, by means of an electrochemicaloxidation-reduction reaction. Batteries are used in a wide variety ofapplications, particularly as a power source for devices that cannotpracticably be powered by centralized power generation sources (e.g., bycommercial power plants using utility transmission lines).

Batteries can be generally described as comprising three components: ananode that contains a material that is oxidized (yields electrons)during discharge of the battery (i.e., while it is providing power); acathode that contains a material that is reduced (accepts electrons)during discharge of the battery; and an electrolyte that provides fortransfer of ions between the cathode and anode. During discharge, theanode is the negative pole of the battery, and the cathode is thepositive pole. Batteries can be more specifically characterized by thespecific materials that make up each of these three components.Selection of these components can yield batteries having specificvoltage and discharge characteristics that can be optimized forparticular applications.

Batteries can also be generally categorized as being “primary,” wherethe electrochemical reaction is essentially irreversible, so that thebattery becomes unusable once discharged; and “secondary,” where theelectrochemical reaction is, at least in part, reversible so that thebattery can be “recharged” and used more than once. Secondary batteriesare increasingly used in many applications, because of their convenience(particularly in applications where replacing batteries can bedifficult), reduced cost (by reducing the need for replacement), andenvironmental benefits (by reducing the waste from battery disposal).

There are a variety of secondary battery systems known in the art. Amongthe most common systems are lead-acid, nickel-cadmium, nickel-zinc,nickel-iron, silver oxide, nickel metal hydride, rechargeablezinc-manganese dioxide, zinc-bromide, metal-air, and lithium batteries.Systems containing lithium and sodium afford many potential benefits,because these metals are light in weight, while possessing high standardpotentials. For a variety of reasons, lithium batteries are, inparticular, commercially attractive because of their high energydensity, higher cell voltages, and long shelf-life.

Lithium batteries are prepared from one or more lithium electrochemicalcells containing electrochemically active (electroactive) materials.Among such batteries are those having metallic lithium anodes and metalchalcogenide (oxide) cathodes, typically referred to as “lithium metal”batteries. The electrolyte typically comprises a salt of lithiumdissolved in one or more solvents, typically nonaqueous aprotic organicsolvents. Other electrolytes are solid electrolytes (typically polymericmatrices) that contain an ionic conductive medium (typically a lithiumcontaining salt dissolved in organic solvents) in combination with apolymer that itself may be ionically conductive but electricallyinsulating.

Cells having a metallic lithium anode and metal chalcogenide cathode arecharged in an initial condition. During discharge, lithium metal yieldselectrons to an external electrical circuit at the anode. Positivelycharged ions are created that pass through the electrolyte to theelectrochemically active (electroactive) material of the cathode. Theelectrons from the anode pass through the external circuit, powering thedevice, and return to the cathode.

Another lithium battery uses an “insertion anode” rather than lithiummetal, and is typically referred to as a “lithium ion” battery.Insertion or “intercalation” electrodes contain materials having alattice structure into which an ion can be inserted and subsequentlyextracted. Rather than chemically altering the intercalation material,the ions slightly expand the internal lattice lengths of the compoundwithout extensive bond breakage or atomic reorganization. Insertionanodes contain, for example, lithium metal chalcogenide, lithium metaloxide, or carbon materials such as coke and graphite. These negativeelectrodes are used with lithium-containing insertion cathodes. In theirinitial condition, the cells are not charged, since the anode does notcontain a source of cations. Thus, before use, such cells must becharged in order to transfer cations (lithium) to the anode from thecathode. During discharge the lithium is then transferred from the anodeback to the cathode. During subsequent recharge, the lithium is againtransferred back to the anode where it reinserts. This back-and-forthtransport of lithium ions (Li+) between the anode and cathode duringcharge and discharge cycles had led to these cells as being called“rocking chair” batteries.

A variety of materials have been suggested for use as cathode activematerials in lithium batteries. Such materials include, for example,MoS₂, MnO₂, TiS₂, NbSe₃, LiCoO₂, LiNiO₂, LiMn₂O₄, V₆O₁₃, V₂O₅, SO₂,CUCl₂. Transition metal oxides, such as those of the general formulaLi_(x)M₂O_(y), are among those materials preferred in such batterieshaving intercalation electrodes. Other materials include lithiumtransition metal phosphates, such as LiFePO₄, and Li₃V₂(PO₄)₃. Suchmaterials having structures similar to olivine or NASICON materials areamong those known in the art. Cathode active materials among those knownin the art are disclosed in S. Hossain, “Rechargeable Lithium Batteries(Ambient Temperature),” Handbook of Batteries, 2d ed., Chapter 36,Mc-Graw Hill (1995); U.S. Pat. No. 4,194,062, Carides, et al., issuedMar. 18, 1980; U.S. Pat. No. 4,464,447, Lazzari, et al., issued Aug. 7,1984; U.S. Pat. No. 5,028,500, Fong et al., issued Jul. 2, 1991; U.S.Pat. No. 5,130,211, Wilkinson, et al., issued Jul. 14, 1992; U.S. Pat.No. 5,418,090, Koksbang et al., issued May 23, 1995; U.S. Pat. No.5,514,490, Chen et al, issued May 7, 1996; U.S. Pat. No. 5,538,814,Kamauchi et al., issued Jul. 23, 1996; U.S. Pat. No. 5,695,893, Arai, etal, issued Dec. 9, 1997; U.S. Pat. No. 5,804,335, Kamauchi, et al.,issued Sep. 8, 1998; U.S. Pat. No. 5,871,866, Barker et al., issued Feb.16, 1999; U.S. Pat. No. 5,910,382, Goodenough, et al., issued Jun. 8,1999; PCT Publication WO/00/31812, Barker, et al., published Jun. 2,2000; PCT Publication WO100/57505, Barker, published Sep. 28, 2000; U.S.Pat. No. 6,136,472, Barker et al., issued Oct. 24, 2000; U.S. Pat. No.6,153,333, Barker, issued Nov. 28, 2000; PCT Publication WO/01/13443,Barker, published Feb. 22, 2001; PCT Publication WO/01154212, Barker etal., published Jul. 26, 2001; PCT Publication WO/01/84655, Barker etal., published Nov. 8, 2001.

In general such a cathode material must exhibit a high free energy ofreaction with lithium, be able to intercalate a large quantity oflithium, maintain its lattice structure upon insertion and extraction oflithium, allow rapid diffusion of lithium, afford good electricalconductivity, not be significantly soluble in the electrolyte system ofthe battery, and be readily and economically produced. However, many ofthe cathode materials known in the art lack one or more of thesecharacteristics. As a result, for example, many such materials are noteconomical to produce, afford insufficient voltage, have insufficientcharge capacity, or lose their ability to be recharged over multiplecycles.

SUMMARY OF THE INVENTION

The invention provides electrode active materials comprising lithium orother alkali metals, a transition metal, and a phosphate or similarmoiety. Such electrode actives include those of the formula:A_(n+x)M_(b)P_(1-x)Si_(x)O₄wherein

-   -   (a) A is selected from the group consisting of Li, Na, K, and        mixtures thereof, and 0<a<1.0; and    -   (b) M comprises one or more metals, comprising at least one        metal which is capable of oxidation to a higher valence state;        and    -   wherein 0<b<2, 0≦x≦1, and M, a, b, and x are selected so as to        maintain electroneutrality of said compound.

In a preferred embodiment, M comprises at least one transition metalselected from Groups 4 to 11 of the Periodic Table. In another preferredembodiment, M comprises M′_(c)M″_(d), where M′ is at least onetransition metal from Groups 4 to 11 of the Periodic Table; and M″ is atleast one element from Groups 2, 3, 12, 13, or 14 of the Periodic Table,and c+d=b. Preferred embodiments include those where 0.2≦a<1.0 and thosewhere 0.1≦a≦0.8. Preferred embodiments include those where 1.0≦b≦1.5.Preferred embodiments include those having a structure similar to themineral olivine (herein “olivines”).

This invention also provides electrodes comprising an electrode activematerial of this invention. Also provided are batteries that comprise afirst electrode having an electrode active material of this invention; asecond electrode having a compatible active material; and anelectrolyte. In a preferred embodiment, the novel electrode material ofthis invention is used as a positive electrode (cathode) activematerial, reversibly cycling lithium ions with a compatible negativeelectrode (anode) active material.

It has been found that the novel electrode materials, electrodes, andbatteries of this invention afford benefits over such materials anddevices among those known in the art. Such benefits include increasedcapacity, enhanced cycling capability, enhanced reversibility, andreduced costs. Specific benefits and embodiments of the presentinvention are apparent from the detailed description set forth herein.It should be understood, however, that the detailed description andspecific examples, while indicating embodiments among those preferred,are intended for purposes of illustration only and are not intended tolimited the scope of the invention.

DESCRIPTION OF THE INVENTION

The present invention provides electrode active materials for use in abattery. As used herein, “battery” refers to a device comprising one ormore electrochemical cells for the production of electricity. Eachelectrochemical cell comprises an anode, a cathode, and an electrolyte.Two or more electrochemical cells may be combined, or “stacked,” so asto create a multi-cell battery having a voltage that is the sum of thevoltages of the individual cells.

The electrode active materials of this invention may be used in theanode, the cathode, or both. Preferably, the active materials of thisinvention are used in the cathode. (As used herein, the terms “cathode”and “anode” refer to the electrodes at which oxidation and reductionoccur, respectively, during battery discharge. During charging of thebattery, the sites of oxidation and reduction are reversed. Also, asused herein, the words “preferred” and “preferably” refer to embodimentsof the invention that afford certain benefits, under certaincircumstances. However, other embodiments may also be preferred, underthe same or other circumstances. Furthermore, the recitation of one ormore preferred embodiments does not imply that other embodiments are notuseful and is not intended to exclude other embodiments from the scopeof the invention.)

Electrode Active Materials:

The present invention provides active materials (herein “electrodeactive materials”) comprising lithium or other alkali metals, atransition metal, and a phosphate or similar moiety. Such electrodeactive materials include those of the formulaA_(n+x)M_(b)P_(1-x)Si_(x)O₄. (As used herein, the word “include,” andits variants, is intended to be non-limiting, such that recitation ofitems in a list is not to the exclusion of other like items that mayalso be useful in the materials, compositions, devices, and methods ofthis invention.)

A is selected from the group consisting of Li (lithium), Na (sodium), K(potassium), and mixtures thereof. In a preferred embodiment, A is Li,or a mixture of Li with Na, a mixture of Li with K, or a mixture of Li,Na and K. In another preferred embodiment, A is Na, or a mixture of Nawith K. Preferably “a” is from about 0.1 to about 0.95, more preferablyfrom about 0.2 to about 0.9, and more preferably from about 0.4 to about0.8.

M comprises one or more metals, comprising at least one metal which iscapable of undergoing oxidation to a higher valence state. In apreferred embodiment, removal of alkali metal from the electrode activematerial is accompanied by a change in oxidation state of at least oneof the metals comprising M. The amount of said metal that is availablefor oxidation in the electrode active material determines the amount ofalkali metal that may be removed. Such concepts are, in generalapplication, well known in the art, e.g., as disclosed in U.S. Pat. No.4,477,541, Fraioli, issued Oct. 16, 1984; and U.S. Pat. No. 6,136,472,Barker, et al., issued Oct. 24, 2000, both of which are incorporated byreference herein.

Referring to the general formula A_(a)M_(b)XO₄ (where XO₄ isP_(1-x)Si_(x)O₄), the amount (a′) of alkali metal that can be removed,as a function of the quantity of M (b′) and valency (V^(M)) ofoxidizable metal, isa′=b′(ΔV^(M)),where ΔV^(M) is the difference between the valence state of the metal inthe active material and a valence state readily available for the metal.(The term oxidation state and valence state are used in the artinterchangeably.) For example, for an active material comprising iron(Fe) in the +2 oxidation state, ΔV^(M)=1, wherein iron may be oxidizedto the +3 oxidation state (although iron may also be oxidized to a +4oxidation state in some circumstances). If b=1 (one atomic unit of Feper atomic unit of material), the maximum amount (a′) of alkali metal(oxidation state +1) that can be removed during cycling of the batteryis 1 (one atomic unit of alkali metal). If b=0.5, the maximum amount of(a′) of alkali metal that can be removed during cycling of the batteryis 0.5.

M may comprise a single metal, or a combination of two or more metals.In embodiments where M is a combination of elements, the value of “b”and the total valence of M in the active material must be such that theresulting active material is electrically neutral (i.e., the positivecharges of all anionic species in the material balance the negativecharges of all cationic species), as further discussed below. The netvalence of M (V^(M)) having a mixture of elements (M¹, M² . . . M^(t))may be represented by the formulaV^(M)=V^(M1) b ₁+V^(M2) b ₂+ . . . V^(Mt) b _(t),where b₁+b₂+ . . . b_(t)=1, and V^(M1) is the oxidation state of M1,V^(M2) is the oxidation state of M², etc. (The net valence of M andother components of the electrode active material is discussed further,below.)

M may be, in general, a metal or metalloid, selected from the groupconsisting of elements from Groups 2-14 of the Periodic Table. Asreferred to herein, “Group” refers to the Group numbers (i.e., columns)of the Periodic Table as defined in the current IUPAC Periodic Table.See, e.g., U.S. Pat. No. 6,136,472, Barlker et al., issued Oct. 24,2000, incorporated by reference herein. In a preferred embodiment, Mcomprises one or more transition metals from Groups 4 to 11. In onepreferred embodiment, M is a +2 oxidation state transition metal. Inanother preferred embodiment, M is a +3 oxidation state transitionmetal. In another preferred embodiment, M comprises a mixture of metals,M′_(c)M″_(d), where M′ is at least one transition metal from Groups 4 to11, M″ is at least one element which is from Groups 2, 3, 12, 13, or 14;and c+d=b, wherein c>0 and d>0. In a preferred embodiment 0<(c+d)≦2,more preferably 0.8≦(c+d)≦1.5, and even more preferably 1≦(c+d)≦1.5.Preferably 0<d<1, preferably 0.01≦d≦0.5, more preferably 0.05≦d≦0.2, andeven more preferably 0.05≦d≦0.1.

In another preferred embodiment, M comprises a mixture of metals, M¹_(e)M² _(f)M³ _(g), wherein M¹ is at least one transition metal fromGroups 4 to 11, M² is at least one non-transition metal having a +2oxidation state selected from Groups 2, and M³ is a non transition metalhaving a +3 oxidation state selected from Group 13, and wherein e+f+g=b.In a preferred embodiment 0<(e+f+g)≦2, more preferably 0.8≦(e+f+g)≦1.5,and even more preferably 1≦(e+f+g)≦1.5, wherein 0’(f+g)<1, preferably0.01≦(f+g)≦0.5, more preferably 0.05≦(f+g)≦0.2, and even more preferably0.05≦(f+g)≦0.1.

Transition metals useful herein include those selected from the groupconsisting of Ti (Titanium), V (Vanadium), Cr (Chromium), Mn(Manganese), Fe (Iron), Co (Cobalt), Ni (Nickel), Cu (Copper), Zr(Zirconium), Nb (Niobium), Mo (Molybdenum), Ru (Ruthenium), Rh(Rhodium), Pd (Palladium), Ag (Silver), Cd (Cadmium), Hf (Hafnium), Ta(Tantalum), W (Tungsten), Re (Rhenium), Os (Osmium), Ir (Iridium), Pt(Platinum), Au (Gold), Hg (Mercury), and mixtures thereof. Preferred arethe first row transition series (the 4th Period of the Periodic Table),selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Cu, andmixtures thereof. Particularly preferred transition metals useful hereinclude Fe, Co, Mn, V, Cr, Ti and mixtures thereof. In some embodiments,mixtures of transition metals are preferred. Although, a variety ofoxidation states for such transition metals are available, in someembodiments it is most preferable that the transition metals have a +2oxidation state.

M may also comprise non-transition metals and metalloids. Among suchelements are those selected from the group consisting of Group 2elements, particularly Be (Beryllium), Mg (Magnesium), Ca (Calcium), Sr(Strontium), Ba (Barium); Group 3 elements, particularly Sc (Scandium),Y (Yttrium), and the lanthanides, particularly La (Lanthanum), Ce(Cerium), Pr (Praseodymium), Nd (Neodymium), Sm (Samarium); Group 12elements, particularly Zn (zinc) and Cd (cadmium); Group 13 elements,particularly B (Boron), Al (Aluminum), Ga (Gallium), In (Indium), Ti(Thallium); Group 14 elements, particularly Si (Silicon), Ge(Germanium), Sn (Tin), and Pb (Lead); Group 15 elements, particularly As(Arsenic), Sb (Antimony), and Bi (Bismuth); Group 16 elements,particularly Te (Tellurium); and mixtures thereof. Preferrednon-transition metals include the Group 2 elements, Group 12 elements,Group 13 elements, and Group 14 elements. Particularly preferrednon-transition metals include those selected from the group consistingof Mg, Ca, Zn, Sr, Pb, Cd, Sn, Ba, Be, Al, and mixtures thereof.Particularly preferred are non-transition metals selected from the groupconsisting of Mg, Ca, Zn, Ba, Al, and mixtures thereof.

The active materials comprise an XO₄ moeity of the formulaP_(1-x)Si_(x)O₄ wherein 0≦x≦1. In one preferred embodiment x=0, suchthat XO₄ is PO₄. In another preferred embodiment 0≦x≦0.8, morepreferably 0≦x≦0.5.

The composition of M, X, and the values of a, b, c, d, and x, areselected so as to maintain electroneutrality of the electrode activematerial. As referred to herein “electroneutrality” is the state of theelectrode active material wherein the sum of the positively chargedspecies (e.g., A and M) in the material is equal to the sum of thenegatively charged species (e.g. XO₄) in the material. Preferably, theXO₄ moieties are comprised to be, as a unit moiety, an anion having acharge ranging from −3 up to −4, depending on the selection of X.

In general, the valence state of each component element of the electrodeactive material may be determined in reference to the composition andvalence state of the other component elements of the material. Byreference to the general formula A_(a)M_(b)XO₄ the electroneutrality ofthe material may be determined using the formula(V^(A))a+(V^(M))b+(V^(X))c=−(V^(O))4where V^(A) is the net valence of A, V^(M) is the net valence of M,V^(O) is the net valence of O (oxygen) which is −2. Therefore:(V^(A))a+(V^(M))b+(V^(X))c=8

As referred to herein, the “net valence” of a component is (a) thevalence state for a component having a single element which occurs inthe active material in a single valence state; or (b) the mole-weightedsum of the valence states of all elements in a component comprising morethan one element, or comprising a single element having more than onevalence state. The net valence of each component is represented in thefollowing formulae:(V^(A))a=[(V^(A1))a ¹+(Val^(A2))a ²+(Val^(An))a ^(n) ]/n; a ¹ +a ² + . .. a ^(n) =a(V^(M))b=[(V^(M1))b ¹+(V^(M2))b ² + . . . (V ^(Mn))b ^(n) ]/n; b ¹ +b² + . . . b ^(n) =b

In general, the quantity and composition of M is selected given thevalue of “x” (i.e., the valency of XO₄), the value of “c,” and theamount of A, so long as M comprises at least one metal that is capableof oxidation. The calculation for the valence of M can be simplified,where V^(A)=1 as follows.(V^(M))b=(V^(A))4+d−a−(V^(X))

The values of a, b, and x, may result in stoichiometric ornon-stoichiometric formulas for the electrode active materials. In apreferred embodiment, the values of a, b, and x, are all integer values,resulting in a stoichiometric formula. In another preferred embodiment,one or more of a, b, and x, may have non-integer values. It isunderstood, however, in embodiments having a lattice structurecomprising multiple units of a non-stoichiometric formula AaMbXO₄, thatthe formula may be stoichiometric when looking at a multiple of the unitThat is, for a unit formula where one or more of a, b, and x, is anon-integer, the values of each variable become an integer value withrespect to a number of units that is the least common multiplier of eachof a, b, and x. For example, the active materialLi_(0.95)Co_(0.9)Al_(0.05)Mg_(0.05)PO₄ is non-stoichiometric. However,in a material comprising twenty of such units in a lattice structure,the formula is Li₉Co₁₈AlMg(PO₄)₂₀.

A preferred electrode active material embodiment comprises a compound

of the formulaLi_(a)M′_(c)M″_(d)PO₄,

-   -   wherein    -   (a) 0<a<1.0;    -   (b) M′ comprises at least one transition metal from Groups 4 to        11 of the Periodic table, where c>0;    -   (c) M″ comprises one or more non-transition metals from Groups        2, 3, 12, 13, or 14 of the Periodic Table, d>0; and    -   wherein M′, M″, a, c, and d are selected so as to maintain        electroneutrality of said compound.        Preferably, M′ is selected from the group consisting of +2 and        +3 oxidation state transition metal, preferably selected from        the group consisting of Fe, Co, Ni, Mn, Cu, V, Zr, Ti, Cr, and        mixtures thereof. In one preferred embodiment M′ is selected        from the group consisting of +2 oxidation state transition        metals including Ti, V, Cr, Mn, Fe, Co, Ni, Cu and mixtures        thereof. In another preferred embodiment, M′ is selected from        the group consisting of +3 oxidation state transition metal        including Ti, V, Cr, Mn, and mixtures thereof. Preferably, M″ is        selected from the group consisting of +2 and +3 oxidation state        non-transition metals including Mg, Ca, Zn, Sr, Pb, Cd, Sn, Ba,        Be, Al, and mixtures thereof; more preferably M″ is selected        from the group consisting of Mg, Ca, Zn, Ba, Al, and mixtures        thereof. In another embodiment, M″ is selected from the group        consisting of +3 oxidation state transition metals including Ti,        V, Cr, and Mn.

Another preferred embodiment comprises a compound of the formulaA_(a)M¹ _(e)M² _(f)M³ _(g)PO₄wherein

-   -   (a) A is selected from the group consisting of Li, Na, K, and        mixtures thereof, where 0<a<1;    -   (b) M¹ comprises one or more transition metals, where 0<e;    -   (c) M² comprises one or more +2 oxidation state non-transition        metals;    -   (d) M³ comprises one or more +3 oxidation state non-transition        metals; and    -   wherein M¹, M², M³, X, a, e, f, and g are selected so as to        maintain electroneutrality of said compound.

Where M¹ is a +2 oxidation state transition metal, a+2e+2f+3g=3.Preferably, 0<(e+f+g)≦2, more preferably 0.8≦(e+f+g)≦1.5, and even morepreferably 1≦(e+f+g)≦1.5, wherein 0<(f+g)<1, preferably 0.01≦(f+g)≦0.5,more preferably 0.05≦(f+g)≦0.2, and even more preferably 0.05≦(f+g)≦0.1.

Preferably, M¹ is at least one transition metal from Groups 4 to 11 ofthe Periodic Table; M² is at least one element from Groups 2, 12, or 14of the Periodic Table, and M³ is selected from the group consisting of+3 oxidation state transition metals selected from Groups 4 to 11, +3oxidation state non-transition metals selected from Groups 3 or 13, ormixtures thereof. Preferably Ml is selected from the group consisting ofFe, Co, Ni, Mn, Cu, V, Zr, Ti, Cr, and mixtures thereof; more preferablyM¹ is a +2 oxidation state transition metal selected from the groupconsisting of Fe, Co, Mn, Cu, V, Cr, and mixtures thereof. Preferably M²is selected from the group consisting +2 oxidation state non-transitionmetals and mixtures thereof; more preferably M² is selected from thegroup consisting of Be, Mg, Ca, Sr, Ba, Ra, Zn, Cd, Hg and mixturesthereof. Preferably, in one embodiment, M³ is a +3 oxidation statetransition metal, preferably M³ is selected from Groups 4 to 11, morepreferably Ti, V, Cr, Mn, Fe, and mixtures thereof. In anotherembodiment, M³ is a +3 oxidation state non-transition metal, preferablyM³ is selected from Groups 3 or 13, more preferably Sc, Y, La, Ac, B,Al, Ga, In, Ti and mixtures thereof.

Another preferred embodiment comprises a compound of the formulaA_(a)M′_(1+(x/2))M″_((1-a)/2)P_(1-x)S_(x)O₄wherein

-   -   (a) A is selected from the group consisting of Li, Na, K, and        mixtures thereof, and 0<a<1;    -   (b) M′ comprises one or more +2 oxidation state transition        metals; and    -   (c) M″ comprises one or more +2 oxidation state non-transition        metals, wherein x=0, and M′, M″, a, and x are selected so as to        maintain electroneutrality of said compound.

Preferably A is Li, or mixtures of Li with Na, K, or mixtures of Na andK. Preferably, M′ is selected from the group consisting of Ti, V, Cr,Mn, Fe, Co, Ni, and mixtures thereof. Preferably, M″ is a +2 oxidationstate non-transition metal selected from the group consisting of Mg, Ca,Zn, Sr, Pb, Cd, Sn, Ba, Be, and mixtures thereof; more preferably, M″ isselected from the group consisting of Mg, Ca, Zn, Ba, and mixturesthereof.

Another preferred embodiment comprises a compound of the formula:A_(a)M′_(1+(x/2))M″_((1-a)/3)P_(1-x)Si_(x)O₄wherein

-   -   (a) A is selected from the group consisting of Li, Na, K, and        mixtures thereof, and 0<a<1;    -   (b) M′ comprises one or more +2 oxidation state metals,        comprising at least one metal which is capable of undergoing        oxidation to a higher valence state; and    -   (c) M″ comprises one or more +3 oxidation state metals,        including transition and non transition metals;    -   wherein x=0, and M′, M″, a, and x are selected so as to maintain        electroneutrality of said compound.        In a preferred embodiment, A comprises Li, or mixtures of Li        with Na or K. In another preferred embodiment, A comprises Na,        K, or mixtures thereof. Preferably, M′ is at least one metal        selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni,        and mixtures thereof. In one embodiment, M′ additionally        comprises a +2 oxidation state non-transition metal selected        from the group consisting of Mg, Ca, Zn, Sr, Pb, Cd, Sn, Ba, Be,        and mixtures thereof; preferably, M′ includes one element        selected from the group consisting of Mg, Ca, Zn, Ba, and        mixtures thereof. In a preferred embodiment, M″ comprises one or        more +3 oxidation state non transition metals from Groups 3 and        13, preferably selected from the group consisting of Sc, Y, La,        B, Al, Ga, In, Ti, and mixtures thereof. In another preferred        embodiment, M″ comprises a +3 oxidation state transition metal        from Groups 4 to 11 of the Periodic Table, preferably selected        from the group consisting of Cr, V, Ti, Mn, and mixtures        thereof.

Among the preferred embodiments of this invention are the followingelectrode active materials: Li_(0.5)V_(0.6)Mg_(0.65)PO₄,Li_(0.25)Fe_(0.7)Al_(0.4) ₅PO₄, Li_(0.5)CoCr_(0.5)SiO₄,Li_(0.95)Co_(0.09)Al_(0.05)MgO_(0.05)PO₄,Li_(0.95)Fe_(0.8)Ca_(0.15)Al_(0.05)PO₄,Li_(0.75)Co_(0.6)Mg_(0.375)V_(0.1)PO₄,Li_(0.25)MnBe_(0.425)Ga_(0.3)SiO₄,Na_(0.75)Fe_(0.6)Mg_(0.375)Cr_(0.1)PO₄,Li_(0.5)Na_(0.25)Mn_(0.6)Ca_(0.375)Al_(0.1)PO₄, Li_(0.5)Mg_(0.25)FePO₄,Li_(0.75)Ca_(0.125)MnPO₄, Na_(0.6)Mg_(0.2)FePO₄,K_(0.25)Ca_(0.375)CoPO₄, Li_(0.4)Mn_(0.2)Ca_(0.5)Fe_(0.5)PO₄,Li_(0.25)Al_(0.25)Mg_(0.25)Co_(0.75)PO₄,Na_(0.55)B_(0.15)Ni_(0.75)Ba_(0.25)PO₄, Li_(0.8)Mg_(0.1)FePO₄,Li_(0.6)Mg_(0.2)FePO₄, Li_(0.7)Al_(0.1)FePO₄, Li_(0.8)Ca_(0.1)FePO₄,Li_(0.8)Zn_(0.1)FePO₄, Li_(0.8)Mg_(0.1)CoPO₄, Li_(0.8)Mg_(0.1)MnPO₄,Li_(0.8)Mg_(0.1)Mn_(0.5)Fe_(0.5)PO₄,Li_(0.6)Mg_(0.2)Mn_(0.5)Fe_(0.5)PO₄,Li_(0.6)Ca_(0.2)Mn_(0.2)Fe_(0.8)PO₄,Li_(0.8)Zn_(0.2)Mn_(0.2)Fe_(0.8)PO₄,Li_(0.6)Ca_(0.2)Co_(0.2)Fe_(0.8)PO₄, Li_(0.8)Mg_(0.1)NiPO₄,Li_(0.8)Mg_(0.1)CuPO₄, Li_(0.7)Al_(0.1)Mn_(0.5)Fe_(0.5)PO₄,Li_(0.4)Al_(0.2)Mn_(0.5)Fe_(0.5)PO₄,Li_(0.7)Al_(0.1)Co_(0.5)Fe_(0.5)PO₄, Li_(0.7)B_(0.1)Co_(0.5)Fe_(0.5)PO₄,Li_(0.7)Al_(0.1)Co_(0.5)Mn_(0.5)PO₄,Li_(0.7)Al_(0.1)Co_(0.5)Ni_(0.5)PO₄,Li_(1.25)Fe_(1.25)Mg_(0.125)P_(0.50)Si_(0.50)O₄, andLi_(1.25)Fe_(1.25)Al_(0.083)P_(0.50)Si_(0.50)O₄

Methods of Manufacture:

Active materials of general formula A_(a+x)M_(b)P_(1-x)Si_(x)O₄ arereadily synthesized by reacting starting materials in a solid statereaction, with or without simultaneous oxidation or reduction of themetal species involved. According to the desired values of a, and b inthe product, starting materials are chosen that contain “a” moles ofalkali metal A from all sources, “b” moles of metals M from all sources,and one mole of P_(1-x)Si_(x)O₄ (XO₄) from all sources, again takinginto account all sources. As discussed below, a particular startingmaterial may be the source of more than one of the components A, M, andXO₄. Alternatively it is possible to run the reaction with an excess ofone or more of the starting materials. In such a case, the stoichiometryof the product will be determined by the limiting reagent among thecomponents A, M, XO₄, Because in such a case at least some of thestarting materials will be present in the reaction product mixture, itis usually desirable to provide exact molar amounts of all the startingmaterials.

Sources of alkali metal include any of a number of salts or ioniccompounds of lithium, sodium, potassium, rubidium or cesium. Lithium,sodium, and potassium compounds are preferred. Preferably, the alkalimetal source is provided in powder or particulate form. A wide range ofsuch materials is well known in the field of inorganic chemistry.Non-limiting examples include the lithium, sodium, and/or potassiumfluorides, chlorides, bromides, iodides, nitrates, nitrites, sulfates,hydrogen sulfates, sulfites, bisulfites, carbonates, bicarbonates,borates, phosphates, hydrogen ammonium phosphates, dihydrogen ammoniumphosphates, silicates, antimonates, arsenates, germinates, oxides,acetates, oxalates, and the like. Hydrates of the above compounds mayalso be used, as well as mixtures. In particular, the mixtures maycontain more than one alkali metal so that a mixed alkali metal activematerial will be produced in the reaction.

Sources of metals M include salts or compounds of any of the transitionmetals, alkaline earth metals, or lanthanide metals, as well as ofnon-transition metals such as aluminum, gallium, indium, thallium, tin,lead, and bismuth. The metal compounds include, without limitation,fluorides, chlorides, bromides, iodides, nitrates, nitrites, sulfates,hydrogen sulfates, sulfites, bisulfites, carbonates, bicarbonates,borates, phosphates, hydrogen ammonium phosphates, dihydrogen ammoniumphosphates, silicates, antimonates, arsenates, germanates, oxides,hydroxides, acetates, oxalates, and the like. Hydrates may also be used,as well as mixtures of metals, as with the alkali metals, so that alkalimetal mixed metal active materials are produced. The metal M in thestarting material may have any oxidation state, depending the oxidationstate required in the desired product and the oxidizing or reducingconditions contemplated, as discussed below. The metal sources arechosen so that at least one metal in the final reaction product iscapable of being in an oxidation state higher than it is in the reactionproduct.

Sources of the desired starting material anions for the phosphates, areprovided by a number of salts or compounds containing positively chargedcations in addition to the source of phosphate (or other XO₄ species).Such cations include, without limitation, metal ions such as the alkalimetals, alkaline metals, transition metals, or other non-transitionmetals, as well as complex cations such as ammonium or quaternaryammonium. The phosphate anion in such compounds may be phosphate,hydrogen ammonium phosphate, or dihydrogen ammonium phosphate. As withthe alkali metal source and metal source discussed above, the phosphateor other XO₄ species, starting materials are preferably provided inparticulate or powder form. Hydrates of any of the above may be used, ascan mixtures of the above.

A starting material may provide more than one of the components A, M,and XO₄, as is evident in the list above. In various embodiments of theinvention, starting materials are provided that combine, for example,the metal and the phosphate, thus requiring only the alkali metal to beadded. In one embodiment, a starting material is provided that containsalkali metal, metal, and phosphate. There is complete flexibility toselect starting materials containing any of the components of alkalimetal A, metal M, and phosphate (or other XO₄ moiety), depending onavailability. Combinations of starting materials providing each of thecomponents may also be used.

In general, any anion may be combined with the alkali metal cation toprovide the alkali metal source starting material, or with the metal Mcation to provide the metal M starting material. Likewise, any cationmay be used as counterion to the phosphate or similar XO₄ component. Itis preferred, however, to select starting materials with counterionsthat give rise to volatile by-products. Thus, it is desirable to chooseammonium salts, carbonates, oxides, hydroxides, and the like wherepossible. Starting materials with these counterions tend to formvolatile by-products such as water, ammonia, and carbon dioxide, whichcan be readily removed from the reaction mixture. This concept is wellillustrated in the Examples below.

The sources of components A, M, and phosphate (or other XO₄ moiety), maybe reacted together in the solid state while heating for a time andtemperature sufficient to make a reaction product. The startingmaterials are provided in powder or particulate form. The powders aremixed together with any of a variety of procedures, such as by ballmilling without attrition, blending in a mortar and pestle, and thelike. Thereafter the mixture of powdered starting materials iscompressed into a tablet and/or held together with a binder material toform a closely cohering reaction mixture. The reaction mixture is heatedin an oven, generally at a temperature of about 400° C. or greater untila reaction product forms. Exemplary times and temperatures for thereaction are given in the Examples below.

Another means for carrying out the reaction at a lower temperature ishydrothermally. In a hydrothermal reaction, the starting materials aremixed with a small amount of a liquid such as water, and placed in apressurized bomb. The reaction temperature is limited to that which canbe achieved by heating the liquid water in a continued volume creatingan increased pressure, and the particular reaction vessel used.

The reaction may be carried out without redox, or if desired underreducing or oxidizing conditions. When the reaction is done withoutredox, the oxidation state of the metal or mixed metals in the reactionproduct is the same as in the starting materials. Oxidizing conditionsmay be provided by running the reaction in air. Thus, oxygen from theair is used to oxidize the starting material containing the transitionmetal.

The reaction may also be carried out with reduction. For example, thereaction may be carried out in a reducing atmosphere such as hydrogen,ammonia, methane, or a mixture of reducing gases. Alternatively, thereduction may be carried out in situ by including in the reactionmixture a reductant that will participate in the reaction to reduce themetal M, but that will produce by-products that will not interfere withthe active material when used later in an electrochemical cell. Oneconvenient reductant to use to make the active materials of theinvention is a reducing carbon. In a preferred embodiment, the reactionis carried out in an inert atmosphere such as argon, nitrogen, or carbondioxide. Such reducing carbon is conveniently provided by elementalcarbon, or by an organic material that can decompose under the reactionconditions to form elemental carbon or a similar carbon containingspecies that has reducing power. Such organic materials include, withoutlimitation, glycerol, starch, sugars, cokes, and organic polymers whichcarbonize or pyrolize under the reaction conditions to produce areducing form of carbon. A preferred source of reducing carbon iselemental carbon.

The stoichiometry of the reduction can be selected along with therelative stoichiometric amounts of the starting components A, M, and PO₄(or other XO₄ moiety). It is usually easier to provide the reducingagent in stoichiometric excess and remove the excess, if desired, afterthe reaction. In the case of the reducing gases and the use of reducingcarbon such as elemental carbon, any excess reducing agent does notpresent a problem. In the former case, the gas is volatile and is easilyseparated from the reaction mixture, while in the latter, the excesscarbon in the reaction product does not harm the properties of theactive material, because carbon is generally added to the activematerial to form an electrode material for use in the electrochemicalcells and batteries of the invention. Conveniently also, the by-productscarbon monoxide or carbon dioxide (in the case of carbon) or water (inthe case of hydrogen) are readily removed from the reaction mixture.

When using a reducing atmosphere, it is difficult to provide less thanan excess of reducing gas such as hydrogen. Under such as a situation,it is preferred to control the stoichiometry of the reaction by theother limiting reagents, as illustrated in the table. Alternatively thereduction may be carried out in the presence of reducing carbon such aselemental carbon. Experimentally, it would be possible to use preciseamounts of reductant carbon as illustrated in the table for the case ofreductant hydrogen to make products of a chosen stoichiometry. However,it is preferred to carry out the carbothermal reduction in a molarexcess of carbon. As with the reducing atmosphere, this is easier to doexperimentally, and it leads to a product with excess carbon dispersedinto the reaction product, which as noted above provides a useful activeelectrode material.

The carbothermal reduction method of synthesis of mixed metal phosphateshas been described in PCT Publication WO/01/53198, Barker et al.,incorporated by reference herein. The carbothermal method may be used toreact starting materials in the presence of reducing carbon to form avariety of products. The carbon functions to reduce a metal ion in thestarting material metal M source. The reducing carbon, for example inthe form of elemental carbon powder, is mixed with the other startingmaterials and heated. For best results, the temperature should be about400° C. or greater, and up to about 950° C. Higher temperatures may beused, but are usually not required.

Generally, higher temperature (about 650° C. to about 1000° C.)reactions produce CO as a by-product whereas CO₂ production is favoredat lower temperatures (generally up to about 650° C.). The highertemperature reactions produce CO effluent and the stoichiometry requiresmore carbon be used than the case where CO₂ effluent is produced atlower temperature. This is because the reducing effect of the C to CO₂reaction is greater than the C to CO reaction. The C to CO₂ reactioninvolves an increase in carbon oxidation state of +4 (from 0 to 4) andthe C to CO reaction involves an increase in carbon oxidation state of+2 (from ground state zero to 2). In principle, such would affect theplanning of the reaction, as one would have to consider not only thestoichiometry of the reductant but also the temperature of the reaction.When an excess of carbon is used, however such concerns do not arise. Itis therefore preferred to use an excess of carbon, and control thestoichiometry of the reaction with another of the starting materials aslimiting reagent.

As noted above, the active materials A_(a)M_(b)XO₄ of the invention cancontain a mixture of alkali metals A, a mixture of metals B, and aphosphate group representative of the XO₄ group in the formula. Thus,active materials are provided according to the invention wherein the XO₄moiety is a phosphate group, wherein the phosphate (P) of the XO₄ moietycan be completely or partially substituted with silicon (Si).

To synthesize the active materials containing the modified phosphatemoieties, it is usually possible to substitute all or part of thephosphate compounds discussed above with a source of the replacementanion. The replacement is considered on a stoichiometric basis and thestarting materials providing the source of the replacement anions areprovided along with the other starting materials as discussed above.Synthesis of the active materials containing the modified phosphategroups proceeds as discussed above, either without redox or underoxidizing or reducing conditions. As was the case with the phosphatecompounds, the compound containing the modified or replacement phosphategroup or groups may also be a source of other components of the activematerials. For example, the alkali metal and/or the mixed metal M may bea part of the modified phosphate compound.

When it is desired to partially or completely substitute phosphorous inthe active materials for silicon, it is possible to use a wide varietyof silicates and other silicon containing compounds. Thus, usefulsources of silicon in the active materials of the invention includeorthosilicates, pyrosilicates, cyclic silicate anions such as (Si₃O₉)⁶⁻,(Si₆O₁₈)₁₂— and the like and pyrocenes represented by the formula[(SiO₃)₂-]n, for example LiAl(SiO₃)₂. Silica or SiO₂ may also be used.Partial substitution of silicate for phosphate is illustrated in thefollowing examples.

To prepare the active materials containing the modified phosphategroups, it suffices to choose the stoichiometry of the startingmaterials based on the desired stoichiometry of the modified phosphategroups in the final product and react the starting materials togetheraccording to the procedures described above with respect to thephosphate materials. Naturally, partial or complete substitution of thephosphate group with any of the above modified or replacement phosphategroups will entail a recalculation of the stoichiometry of the requiredstarting materials.

In a preferred embodiment, a one step method is used to prepare thegeneral formula LiMPO₄. The starting (precursor) materials for the firststep include a lithium containing compound, a metal containing compoundand a phosphate containing compound. Each of these compounds may beindividually available or may be incorporated within the same compounds,such as a lithium metal compound or a metal phosphate compound.

In one method of this invention, the starting materials are intimatelymixed and then reacted together when initiated by heat. In general, themixed powders are pressed into a pellet. The pellet is then heated to anelevated temperature. This reaction can be run under an air atmosphereor a non-oxidizing atmosphere. In another method, the lithium metalphosphate compound can be formed either by a carbothermal reaction, orby a hydrogen reduction reaction.

The general aspects of the above synthesis route are applicable to avariety of starting materials. The metal compounds may be reduced in thepresence of a reducing agent, such as hydrogen or carbon. The sameconsiderations apply to other metal and phosphate containing startingmaterials. The thermodynamic considerations such as ease of reduction ofthe selected starting materials, the reaction kinetics, and the meltingpoint of the salts will cause adjustment in the general procedure, suchas the amount of reducing agent, the temperature of the reaction, andthe dwell time.

The method includes reacting a lithium containing compound (lithiumcarbonate, Li₂CO₃), a metal containing compound having a phosphate group(for example, nickel phosphate, Ni₃(PO₄)_(2-x)H₂O, which usually hasmore than one mole of water), and a phosphoric acid derivative (such asa diammonium hydrogen phosphate, DAHP). The powders are pre-mixed with amortar and pestle until uniformly dispersed, although various methods ofmixing may be used. The mixed powders of the starting materials arepressed into pellets. The first stage reaction is conducted by heatingthe pellets in an oven at a preferred heating rate to an elevatedtemperature, and held at such elevated temperature for several hours. Apreferred ramp rate of about 2° C./minute is used to heat to apreferable temperature of about 800° C. Although in many instances aheating rate is desirable for a reaction, it is not always necessary forthe success of the reaction. The reaction is carried out under a flowingair atmosphere (e.g., when M is Ni or Co), although the reaction couldbe carried out in an inert atmosphere such as N₂ or Ar (when M is Fe).The flow rate will depend on the size of the oven and the quantityneeded to maintain the atmosphere. The reaction mixture is held at theelevated temperature for a time sufficient for the reaction product tobe formed. The pellets are then allowed to cool to ambient temperature.The rate at which a sample is cooled may vary.

Electrodes:

The present invention also provides electrodes comprising an electrodeactive material of the present invention. In a preferred embodiment, theelectrodes of the present invention comprise an electrode activematerial of this invention, a binder; and an electrically conductivecarbonaceous material.

In a preferred embodiment, the electrodes of this invention comprise:

-   -   (a) from about 25% to about 95%, more preferably from about 50%        to about 90%, active material;    -   (b) from about 2% to about 95% electrically conductive material        (e.g., carbon black); and    -   (c) from about 3% to about 20% binder chosen to hold all        particulate materials in contact with one another without        degrading ionic conductivity.        (Unless stated otherwise, all percentages herein are by weight.)        Cathodes of this invention preferably comprise from about 50% to        about 90% of active material, about 5% to about 30% of the        electrically conductive material, and the balance comprising        binder. Anodes of this invention preferably comprise from about        50% to about 95% by weight of the electrically conductive        material (e.g., a preferred graphite), with the balance        comprising binder.

Electrically conductive materials among those useful herein includecarbon black, graphite, powdered nickel, metal particles, conductivepolymers (e.g., characterized by a conjugated network of double bondslike polypyrrole and polyacetylene), and mixtures thereof. Bindersuseful herein preferably comprise a polymeric material and extractableplasticizer suitable for forming a bound porous composite. Preferredbinders include halogenated hydrocarbon polymers (such aspoly(vinylidene chloride) and poly((dichloro-1,4-phenylene)ethylene),fluorinated urethanes, fluorinated epoxides, fluorinated acrylics,copolymers of halogenated hydrocarbon polymers, epoxides, ethylenepropylene diamine termonomer (EPDM), ethylene propylene diaminetermonomer (EPDM), polyvinylidene difluoride (PVDF), hexafluoropropylene(HFP), ethylene acrylic acid copolymer (EAA), ethylene vinyl acetatecopolymer (EVA), EAA/EVA copolymers, PVDF/HFP copolymers, and mixturesthereof.

In a preferred process for making an electrode, the electrode activematerial is mixed into a slurry with a polymeric binder compound, asolvent, a plasticizer, and optionally the electroconductive material.The active material slurry is appropriately agitated, and then thinlyapplied to a substrate via a doctor blade. The substrate can be aremovable substrate or a functional substrate, such as a currentcollector (for example, a metallic grid or mesh layer) attached to oneside of the electrode film. In one embodiment, heat or radiation isapplied to evaporate the solvent from the electrode film, leaving asolid residue. The electrode film is further consolidated, where heatand pressure are applied to the film to sinter and calendar it. Inanother embodiment, the film may be air-dried at moderate temperature toyield self-supporting films of copolymer composition. If the substrateis of a removable type it is removed from the electrode film, andfurther laminated to a current collector. With either type of substrateit may be necessary to extract the remaining plasticizer prior toincorporation into the battery cell.

Batteries:

The batteries of the present invention comprise.

(a) a first electrode comprising an active material of the presentinvention;

(b) a second electrode which is a counter-electrode to said firstelectrode; and

(c) an electrolyte between said electrodes.

The electrode active material of this invention may comprise the anode,the cathode, or both. Preferably, the electrode active materialcomprises the cathode.

The active material of the second, counter-electrode is any materialcompatible with the electrode active material of this invention. Inembodiments where the electrode active material comprises the cathode,the anode may comprise any of a variety of compatible anodic materialswell known in the art, including lithium, lithium alloys, such as alloysof lithium with aluminum, mercury, manganese, iron, zinc, andintercalation based anodes such as those employing carbon, tungstenoxides, and mixtures thereof. In a preferred embodiment, the anodecomprises:

-   -   (a) from about 0% to about 95%, preferably from about 25% to        about 95%, more preferably from about 50% to about 90%, of an        insertion material;    -   (b) from about 2% to about 95% electrically conductive material        (e.g., carbon black); and    -   (c) from about 3% to about 20% binder chosen to hold all        particulate materials in contact with one another without        degrading ionic conductivity.        In a particularly preferred embodiment, the anode comprises from        about 50% to about 90% of an insertion material selected from        the group active material from the group consisting of metal        oxides (particularly transition metal oxides), metal        chalcogenides, and mixtures thereof. In another preferred        embodiment, the anode does not contain an insertion active, but        the electrically conductive material comprises an insertion        matrix comprising carbon, graphite, cokes, mesocarbons and        mixtures thereof. One preferred anode intercalation material is        carbon, such as coke or graphite, which is capable of forming        the compound Li_(x)C. Insertion anodes among those useful herein        are described in U.S. Pat. No. 5,700,298, Shi et al., issued        Dec. 23, 1997; U.S. Pat. No. 5,712,059, Barker et al., issued        Jan. 27, 1998; U.S. Pat. No. 5,830,602, Barker et al., issued        Nov. 3, 1998; and U.S. Pat. No. 6,103,419, Saidi et al., issued        Aug. 15, 2000; all of which are incorporated by reference        herein.

In embodiments where the electrode active material comprises the anode,the cathode preferably comprises:

-   -   (a) from about 25% to about 95%, more preferably from about 50%        to about 90%, active material;    -   (b) from about 2% to about 95% electrically conductive material        (e.g., carbon black); and    -   (c) from about 3% to about 20% binder chosen to hold all        particulate materials in contact with one another without        degrading ionic conductivity.        Active materials useful in such cathodes include electrode        active materials of this invention, as well as metal oxides        (particularly transition metal oxides), metal chalcogenides, and        mixtures thereof. Other active materials include lithiated        transition metal oxides such as LiCoO₂, LiNiO₂, and mixed        transition metal oxides such as LiCo_(1-m)Ni_(m)O₂, where 0<m<1.        Another preferred active material includes lithiated spinel        active materials exemplified by compositions having a structure        of LiMn₂O₄, as well as surface treated spinels such as disclosed        in U.S. Pat. No. 6,183,718, Barker et al., issued Feb. 6, 2001,        incorporated by reference herein. Blends of two or more of any        of the above active materials may also be used. The cathode may        alternatively further comprise a basic compound to protect        against electrode degradation as described in U.S. Pat. No.        5,869,207, issued Feb. 9, 1999, incorporated by reference        herein.

The batteries of this invention also comprise a suitable electrolytethat provides for transfer of ions between the cathode and anode. Theelectrolyte is preferably a material that exhibits high ionicconductivity, as well as having insular properties to preventself-discharging during storage. The electrolyte can be either a liquidor a solid. Solid electrolytes preferably comprise a polymeric matrixwhich contains an ionic conductive medium. A liquid electrolytepreferably comprises a solvent and an alkali metal salt that form anionically conducting liquid.

One preferred embodiment is a solid polymeric electrolyte, comprising asolid polymeric matrix of an electrolyte compatible material formed bypolymerizing an organic or inorganic monomer (or partial polymerthereof) and which, when used in combination with the other componentsof the electrolyte, results in a solid state electrolyte. Suitable solidpolymeric matrices include those well known in the art and include solidmatrices formed from organic polymers, inorganic polymers or a solidmatrix forming monomer and from partial polymers of a solid matrixforming monomer.

The polymeric electrolyte matrix comprises a salt, typically inorganic,which is homogeneously dispersed via a solvent vehicle throughout thematrix. The solvent is preferably a low molecular weight organic solventadded to the electrolyte, which may serve the purpose of solvating theinorganic ion salt. The solvent is preferably any compatible, relativelynon-volatile, aprotic, relatively polar solvent, including dimethylcarbonate (DMC), diethyl carbonate (DEC), dipropylcarbonate (DPC), ethylmethyl carbonate (EMC), butylene carbonate, gamma-butyrolactone,triglyme, tetraglyme, lactones, esters, dimethylsulfoxide, dioxolane,sulfolane, and mixtures thereof. Preferred solvents include EC/DMC,EC/DEC, EC/DPC and EC/EMC. Preferably, the inorganic ion salt is alithium or sodium salt, such as for example, LiAsF₆, LiPF₆, LiClO₄,LiB(C₆H₅)₄, LiAlCl₄, LiBr, and mixtures thereof, with the less toxicsalts being preferable. The salt content is preferably from about 5% toabout 65%, preferably from about 8% to about 35%. A preferred embodimentis a mixture of EC:DMC:LiPF₆ in a weight ratio of about 60:30:10.Electrolyte compositions among those useful herein are described in U.S.Pat. No. 5,418,091, Gozdz et al., issued May 23, 1995; U.S. Pat. No.5,508,130, Golovin, issued Apr. 16, 1996; U.S. Pat. No. 5,541,020,Golovin et al, issued Jul. 30, 1996; U.S. Pat. No. 5,620,810, Golovin etal., issued Apr. 15, 1997; U.S. Pat. No. 5,643,695, Barker et al.,issued Jul. 1, 1997; U.S. Pat. No. 5,712,059, Barker et al., issued Jan.27, 1997; U.S. Pat. No. 5,851,504, Barker et al., issued Dec. 22, 1998;U.S. Pat. No. 6,020,087, Gao, issued Feb. 1, 2001; and U.S. Pat. No.6,103,419, Saidi et al., issued Aug. 15, 2000; all of which areincorporated by reference herein.

Additionally, the electrolyte comprises a separator, or is surrounded bya separator membrane. The separator allows the migration of ions throughthe membrane while still providing a physical separation of the electriccharge between the electrodes, to prevent short-circuiting. Preferably,the separator also inhibits elevated temperatures within the batterythat can occur due to uncontrolled reactions, preferably by degradingupon high temperatures to provide infinite resistance to prevent furtheruncontrolled reactions. In a preferred embodiment, the polymeric matrixof the electrolyte can contain an additional polymer (a separator) orthe original polymeric matrix itself may function as a separator,providing the physical isolation needed between the anode and cathode.

A preferred electrolyte separator film comprises approximately two partspolymer for every one part of a preferred fumed silica. The conductivesolvent comprises any number of suitable solvents and salts. Desirablesolvents and salts are described in U.S. Pat. No. 5,643,695, Barker etal, issued Jul. 1, 1997; and U.S. Pat. No. 5,418,091, Gozdz et al.,issued May 23, 1995; both of which are incorporated by reference herein.One example is a mixture of EC:DMC:LiPF₆ in a weight ratio of about60:30:10.

A separator membrane element is generally polymeric and prepared from acomposition comprising a copolymer. A preferred composition is the 75 to92% vinylidene fluoride with 8 to 25% hexafluoropropylene copolymer(available commercially from Atochem North America as Kynar FLEX) and anorganic solvent plasticizer. Such a copolymer composition is alsopreferred for the preparation of the electrode membrane elements, sincesubsequent laminate interface compatibility is ensured. The plasticizingsolvent may be one of the various organic compounds commonly used assolvents for electrolyte salts, e.g., propylene carbonate or ethylenecarbonate, as well as mixtures of these compounds. Higher-boilingplasticizer compounds such as dibutyl phthalate, dimethyl phthalate,diethyl phthalate, and tris butoxyethyl phosphate are preferred.Inorganic filler adjuncts, such as fumed alumina or silanized fumedsilica, may be used to enhance the physical strength and melt viscosityof a separator membrane and, in some compositions, to increase thesubsequent level of electrolyte solution absorption.

A preferred battery comprises a laminated cell structure, comprising ananode layer, a cathode layer, and electrolyte/separator between theanode and cathode layers. The anode and cathode layers comprise acurrent collector. A preferred current collector is a copper collectorfoil, preferably in the form of an open mesh grid. The current collectoris connected to an external current collector tab, for a description oftabs and collectors. Such structures are disclosed in, for example, U.S.Pat. No. 4,925,752, Fauteux et al, issued May 15, 1990; U.S. Pat. No.5,011,501, Shackle et al., issued Apr. 30, 1991; and U.S. Pat. No.5,326,653, Chang, issued Jul. 5, 1994; all of which are incorporated byreference herein. In a battery embodiment comprising multipleelectrochemical cells, the anode tabs are preferably welded together andconnected to a nickel lead. The cathode tabs are similarly welded andconnected to a welded lead, whereby each lead forms the polarized accesspoints for the external load.

Lamination of assembled cell structures is accomplished by conventionalmeans by pressing between metal plates at a temperature of about120-160° C. Subsequent to lamination, the battery cell material may bestored either with the retained plasticizer or as a dry sheet afterextraction of the plasticizer with a selective low-boiling pointsolvent. The plasticizer extraction solvent is not critical, andmethanol or ether are often used.

In a preferred embodiment, a electrode membrane comprising the electrodeactive material (e.g., an insertion material such as carbon or graphiteor a insertion compound) dispersed in a polymeric binder matrix. Theelectrolyte/separator film membrane is preferably a plasticizedcopolymer, comprising a polymeric separator and a suitable electrolytefor ion transport. The electrolyte/separator is positioned upon theelectrode element and is covered with a positive electrode membranecomprising a composition of a finely divided lithium insertion compoundin a polymeric binder matrix. An aluminum collector foil or gridcompletes the assembly. A protective bagging material covers the celland prevents infiltration of air and moisture.

In another embodiment, a multi-cell battery configuration may beprepared with copper current collector, a negative electrode, anelectrolyte/separator, a positive electrode, and an aluminum currentcollector. Tabs of the current collector elements form respectiveterminals for the battery structure.

In a preferred embodiment of a lithium-ion battery, a current collectorlayer of aluminum foil or grid is overlaid with a positive electrodefilm, or membrane, separately prepared as a coated layer of a dispersionof insertion electrode composition. This is preferably an insertioncompound such as the active material of the present invention in powderform in a copolymer matrix solution, which is dried to form the positiveelectrode. An electrolyte/separator membrane is formed as a driedcoating of a composition comprising a solution containing VdF:HFPcopolymer and a plasticizer solvent is then overlaid on the positiveelectrode film. A negative electrode membrane formed as a dried coatingof a powdered carbon or other negative electrode material dispersion ina VdF:HFP copolymer matrix solution is similarly overlaid on theseparator membrane layer. A copper current collector foil or grid islaid upon the negative electrode layer to complete the cell assembly.Therefore, the VdF:HFP copolymer composition is used as a binder in allof the major cell components, positive electrode film, negativeelectrode film, and electrolyte/separator membrane. The assembledcomponents are then heated under pressure to achieve heat-fusion bondingbetween the plasticized copolymer matrix electrode and electrolytecomponents, and to the collector grids, to thereby form an effectivelaminate of cell elements. This produces an essentially unitary andflexible battery cell structure.

Cells comprising electrodes, electrolytes and other materials amongthose useful herein are described in the following documents, all ofwhich are incorporated by reference herein: U.S. Pat. No. 4,668,595,Yoshino et al., issued May 26, 1987; U.S. Pat. No. 4,792,504, Schwab etal., issued Dec. 20, 1988; U.S. Pat. No. 4,830,939, Lee et al., issuedMay 16, 1989; U.S. Pat. No. 4,935,317, Fauteaux et al., issued Jun. 19,1980; U.S. Pat. No. 4,990,413, Lee et al., issued Feb. 5, 1991; U.S.Pat. No. 5,037,712, Shackle et al., issued Aug. 6, 1991; U.S. Pat. No.5,262,253, Golovin, issued Nov. 16, 1993; U.S. Pat. No. 5,300,373,Shackle, issued Apr. 5, 1994; U.S. Pat. No. 5,399,447, Chaloner-Gill, etal., issued Mar. 21, 1995; U.S. Pat. No. 5,411,820, Chaloner-Gill,issued May 2, 1995; U.S. Pat. No. 5,435,054, Tonder et al., issued Jul.25, 1995; U.S. Pat. No. 5,463,179, Chaloner-Gill et al., issued Oct. 31,1995; U.S. Pat. No. 5,482,795, Chaloner-Gill., issued Jan. 9, 1996; U.S.Pat. No. 5,660,948, Barker, issued Sep. 16, 1995; and U.S. Pat. No.6,306,215, Larkin, issued Oct. 23, 2001. A preferred electrolyte matrixcomprises organic polymers, including VdF:HFP. Examples of casting,lamination and formation of cells using VdF:HFP are as described in U.S.Pat. Nos. 5,418,091, Gozdz et al., issued May 23, 1995; U.S. Pat. No.5,460,904, Gozdz et al., issued Oct. 24, 1995; U.S. Pat. No. 5,456,000,Gozdz et al., issued Oct. 10, 1995; and U.S. Pat. No. 5,540,741, Gozdzet al., issued Jul. 30, 1996; all of which are incorporated by referenceherein.

The electrochemical cell architecture is typically governed by theelectrolyte phase. A liquid electrolyte battery generally has acylindrical shape, with a thick protective cover to prevent leakage ofthe internal liquid. Liquid electrolyte batteries tend to be bulkierrelative to solid electrolyte batteries due to the liquid phase andextensive sealed cover. A solid electrolyte battery, is capable ofminiaturization, and can be shaped into a thin film. This capabilityallows for a much greater flexibility when shaping the battery andconfiguring the receiving apparatus. The solid state polymer electrolytecells can form flat sheets or prismatic (rectangular) packages, whichcan be modified to fit into the existing void spaces remaining inelectronic devices during the design phase.

The following non-limiting examples illustrate the active materials,compositions and methods of the present invention.

EXAMPLE 1

An electrode active material comprising Li_(0.5)Ni_(1.25)PO₄,representative of the formula Li_(a)Ni_(b)PO₄, is made according to thefollowing reaction scheme.0.25 Li₂CO₃+0.417 Ni₃(PO₄)₂.7H₂O+0.166(NH₄)₂HPO₄→Li_(0.5)Ni_(1.25)PO₄+2.919 H₂O+0.332 NH₃+0.25 CO₂A mixture of 18.475 g (0.25 mol) of Li₂CO₃, 204.77 g (0.417 mol) ofNi₃(PO₄)₂.7H₂O, and 21.92 g (0.166 mol) of (NH₄)₂HPO₄ is made, using amortar and pestle. The mixture is pelletized, and transferred to a boxoven equipped with an atmospheric air gas flow. The mixture is heated,at a ramp rate of about 2° C. minute to an ultimate temperature of about800° C., and maintained at this temperature for 16 hours. The product isthen cooled to ambient temperature (about 21° C.).

A cathode electrode is made comprising the Li_(0.5)Ni_(1.25)PO₄electrode active material, comprising 80% of the electrode activematerial; 8% Super P carbon; and 12% KYNAR® binder. (KYNAR® is acommercially available PVdF:HFP copolymer used as binder material.) Abattery is made comprising the cathode, a lithium metal anode, and anelectrolyte comprising a 1 molar LiPF₆ dissolved in a 2:1 weight ratiomixture of EC and DMC.

EXAMPLE 2

An electrode active material comprising Li_(0.75)Co_(1.125)PO₄ is madeaccording to the following reaction scheme.0.25 Li₃PO₄+0.375 Co₃(PO₄)₂.8H₂O→Li_(0.75)Co_(1.125)PO₄+3 H₂OA mixture of 28.39 g (0.25 mol ) of Li₃PO₄ and 191.194 g (0.375 mol) ofCo₃(PO₄)₂.8H₂O is made, using a mortar and pestle. The mixture ispelletized, and transferred to a box oven equipped with a atmosphere airgas flow. The mixture is heated at a ramp rate of about 2°/minute to anultimate temperature of about 800° C., and maintained at thistemperature for about 8 hours. The product is then cooled to about 25°C.

EXAMPLE 3

An electrode active material comprising Li_(0.8)Mg_(0.1)FePO₄, madeaccording to the following reaction scheme.0.4 Li₂CO₃+0.1 Mg(OH)₂+0.5 Fe₂O₃+0.5 C+1.0(NH₄)₂HPO₄→Li_(0.8)Mg_(0.1)FePO₄+1.6 H₂O+2 NH₃+0.5 CO+0.4 CO₂A mixture of 29.56 g (0.4 mol) of Li₂CO₃, 5.83 g (0.1 mol) of Mg(OH)₂,79.85 g (0.5 mol) of Fe₂O₃, 6.00 g (0.5 mol) of carbon (although may useup to 100% excess) and 132.06 g (1.0 mol) of (NH₄)₂HPO₄ is made, using amortar and pestle. The mixture is pelletized, and transferred to a boxoven equipped with an inert atmospheric condition. The mixture isheated, at a ramp rate of about 2° C. minute to an ultimate temperatureof about 650-850° C., over a 48 hour period. The product is then cooledto ambient temperature (about 21° C.). It is possible that the materialcan be re-fired if necessary.

EXAMPLE 4

An electrode active material comprising Li_(0.7)Al_(0.1)FePO₄, madeaccording to the following reaction scheme.0.35 Li₂CO₃+0.1 Al(OH)₃+0.5 Fe₂O₃+0.5 C+1.0(NH₄)₂HPO₄→Li_(0.7)Al_(0.1)FePO₄+1.65 H₂O+2 NH₃+0.5 CO+0.35 CO₂A mixture of 25.86 g (0.35 mol) of Li₂CO₃, 7.80 g (0.1 mol) of Al(OH)₃,79.85 g (0.5 mol) Fe₂O₃, 6.00 g (0.5 mol) of carbon (although may use upto 100% excess) and 132.06 g (1.0 mol) of (NH₄)₂HPO₄ is made, using amortar and pestle. The mixture is pelletized, and transferred to a boxoven equipped with an inert atmospheric condition. The mixture isheated, at a ramp rate of about 2° C. minute to an ultimate temperatureof about 650-850° C., over a 48 hour period. The product is then cooledto ambient temperature (about 21° C.). It is possible that the materialcan be re-fired if necessary.

EXAMPLE 5

An electrode active material comprisingLi_(0.8)Mg_(0.1)Mn_(0.5)Fe_(0.5)PO₄, made according to the followingreaction scheme.

A mixture of 29.60 g (0.4 mol) of Li₂CO₃, 5.83 g (0.1 mol) of Mg(OH)₂,35.47 g (0.5 mol) of MnO, 39.93 g (0.25 mol) Fe₂O₃, 3.00 g (0.25 mol) ofcarbon (although may use up to 100% excess) and 132.06 g (1.0 mol) of(NH₄)₂HPO₄ is made, using a mortar and pestle. The mixture ispelletized, and transferred to a box oven equipped with an inertatmospheric condition. The mixture is heated, at a ramp rate of about 2°C. minute to an ultimate temperature of about 650-850° C., over a 48hour period. The product is then cooled to ambient temperature (about21° C.). It is possible that the material can be re-fired if necessary.

EXAMPLE 6

An electrode active material comprising Li_(0.5)Mg_(0.65)Co_(0.6)PO₄,made according to the following reaction scheme.0.25 Li₂CO₃+0.65 Mg(OH)₂+0.6CoO+1.0(NH₄)₂HPO₄→Li_(0.5)Mg_(0.65)Co_(0.6)PO₄+2.15 H₂O+2 NH₃+0.25 CO₂A mixture of 18.47 g (0.25 mol) of Li₂CO₃, 37.91 g (0.65 mol) ofMg(OH)₂, 44.96 g (0.6 mol) of CoO, and 132.06 g (1.0 mol) of (NH₄)₂HPO₄is made, using a mortar and pestle. The mixture is pelletized, andtransferred to a box oven equipped with an inert atmospheric condition.The mixture is heated, at a ramp rate of about 2° C. minute to anultimate temperature of about 650-850° C., over a 48 hour period. Theproduct is then cooled to ambient temperature (about 21° C.). It ispossible that the material can be re-fired if necessary.

1. A battery, comprising: a first electrode comprising an electrodeactive material represented by the formulaA_(a)M′M″_((1-a)/2)PO₄, wherein: (i) A is selected from the groupconsisting of Li, Na, K, and mixtures thereof, where 0<a<1.0; (ii) M′comprises one or more +2 oxidation state metals, comprising at least onemetal which is capable of undergoing oxidation to a higher valencestate; and (iii) M″ comprises one or more +2 oxidation state metals; thebattery further comprising a second electrode; and an electrolyte fortransferring ions between the first electrode and the second electrode.2. The battery according to claim 1, wherein A is Li.
 3. The batteryaccording to claim 1, wherein A is a mixture of Li with Na or K.
 4. Thebattery according to claim 1, wherein A is selected from the groupconsisting of Na, K, and a mixture thereof.
 5. The battery according toclaim 1, wherein M′ is selected from the group consisting of Fe, Co, Ni,Ti, V, Cr, Mn, and mixtures thereof.
 6. The battery according to claim5, wherein M′ is Fe.
 7. The battery according to claim 5, wherein M′ isCo.
 8. The battery according to claim 5, wherein M″ comprises a +2oxidation state non-transition metal selected from the group consistingof Mg, Ca, Zn, Sr, Pb, Cd, Sn, Ba, Be, and mixtures thereof.
 9. Thebattery according to claim 8, wherein M″ comprises a +2 oxidation statenon-transition metal selected from the group consisting of Mg, Ca, Zn,Ba, and mixtures thereof.
 10. The battery according to claim 8, whereinA is Li.
 11. The battery according to claim 1, wherein M″ comprises a +2oxidation state non-transition metal selected from the group consistingof Mg, Ca, Zn, Sr, Pb, Cd, Sn, Ba, Be, and mixtures thereof.
 12. Thebattery according to claim 11, wherein M″ comprises a +2 oxidation statenon-transition metal selected from the group consisting of Mg, Ca, Zn,Ba, and mixtures thereof.
 13. The battery according to claim 11, whereinA is Li.
 14. The battery according to claim 1, wherein the secondelectrode comprises an intercalation material selected from the groupconsisting of a metal oxide, metal chalcogenide, carbon, graphite, andmixtures thereof.
 15. The battery according to claim 14, wherein theintercalation material is graphite.
 16. The battery according to claim14, wherein the electrolyte comprises a solvent selected from the groupconsisting of dimethyl carbonate (DMC), diethyl carbonate (DEC),dipropylcarbonate (DPC), ethyl methyl carbonate (EMC), butylenecarbonate, gamma-butyrolactone, triglyme, tetraglyme, lactones, esters,dimethylsulfoxide, dioxolane, sulfolane, and mixtures thereof,
 17. Thebattery according to claim 16, wherein the solvent further comprises asalt selected from the group consisting of LiAsF₆, LiPF₆, LiClO₄,LiB(C₆H₅)₄, LiAlCl₄, LiBr, and mixtures thereof.
 18. The batteryaccording to claim 14, wherein M is selected from the group consistingof Fe, Co, Ni, Ti, V, Cr, Mn, and mixtures thereof.
 19. The batteryaccording to claim 18, wherein M″ comprises a +2 oxidation statenon-transition metal selected from the group consisting of Mg, Ca, Zn,Sr, Pb, Cd, Sn, Ba, Be, and mixtures thereof.
 20. The battery accordingto claim 19, wherein the intercalation material is graphite.